Modular door lite components

ABSTRACT

Modular components of modular door lite frame systems are disclosed. In some cases, a modular door lite frame system includes matching first and second modular frames, one or more modular male alignment members, and one or more modular female alignment members. In some cases, the modular alignment members can be coupled to modular frames of various sizes. In some cases, the modular components can be formed by casting ABS between no more than two opposed mold portions.

BACKGROUND Technical Field

Modular door lite frame system components and molds for forming suchcomponents are disclosed. Molds for forming the components can includeat most two opposed mold portions.

Description of the Related Art

Existing frame assemblies for door lites are typically pre-manufacturedand shipped to another destination for assembly and installation. Forexample, door lite frame assemblies can come in two sub-parts, which aresecured together with a piece of glass or other transparent orinsulating material, such as a glazing panel, between the two sub-parts.There are many existing frame assemblies having different types ofexternal clips or other external fasteners (such as screws) for securingthe frame assembly together.

Unfortunately, installation of these existing door lite frames withexternal fasteners can be time consuming. For example, in some priordoor lite frames, when the frame assembly arrives at the place ofinstallation, the frame sub-parts are typically separated by removingfasteners that hold the sub-parts together during transportation. Thenduring installation, the frame sub-parts are positioned and re-securedtogether with fasteners. Each fastener that is removed after shipmentand re-secured during installation decreases the efficiency ofinstallation, increases costs, and detracts from the aesthetics of thedoor lite frame.

Door lites without external threaded fasteners have been the subject ofU.S. patent applications. For example, U.S. Patent ApplicationPublication No. 2010/0064625 to Charlton et al., the full disclosure ofwhich is hereby incorporated herein by reference in its entirety,describes a door lite frame system. One drawback of such door lite framesystems is that they have been found to be more expensive than desirableto fabricate. There is a need for relatively inexpensive door lite framesystems, components thereof, molds for forming such components, andsystems including such components.

BRIEF SUMMARY

In some embodiments, a mold system for casting door lite frame systemcomponents comprises a first mold including a first top mold portion anda first bottom mold portion, the first top mold portion and the firstbottom mold portion defining a first cavity for casting a first modularframe having a first length, a first width, and a first recess havingfirst recess dimensions, a second mold including a second top moldportion and a second bottom mold portion, the second top mold portionand the second bottom mold portion defining a second cavity for castinga second modular frame having a second length larger than the firstlength, a second width larger than the first width, and a second recesshaving second recess dimensions, the second recess dimensions being thesame as the first recess dimensions, a third mold including a third topmold portion and a third bottom mold portion, the third top mold portionand the third bottom mold portion defining a third cavity for casting amale alignment member having male alignment member dimensions such thatthe male alignment member can be seated within the first recess and canbe seated within the second recess, and a fourth mold including a fourthtop mold portion and a fourth bottom mold portion, the fourth top moldportion and the fourth bottom mold portion defining a fourth cavity forcasting a female alignment member having female alignment memberdimensions such that the female alignment member can be seated withinthe first recess and can be seated within the second recess.

In some cases, the third top mold portion and the third bottom moldportion define the third cavity for casting a male interlocking memberhaving a plurality of arms extending therefrom, and the fourth top moldportion and the fourth bottom mold portion define the fourth cavity forcasting the female alignment member including a plurality of teeth toengage with the plurality of arms.

In other embodiments, a system of door lite components comprises a firstmodular frame including a first recess and a second modular frameincluding a second recess, the first modular frame having dimensionsmatching those of the second modular frame, the first modular frame andthe second modular frame having a first length and a first width, athird modular frame including a third recess and a fourth modular frameincluding a fourth recess, the third modular frame having dimensionsmatching those of the fourth modular frame, the third modular frame andthe fourth modular frame having a second length larger than the firstlength and a second width larger than the first width, a first malealignment member and a second male alignment member, the first malealignment member having dimensions matching those of the second malealignment member, a first female alignment member and a second femalealignment member, the first female alignment member having dimensionsmatching those of the second female alignment member, wherein the firstmale alignment member, the second male alignment member, the firstfemale alignment member, and the second female alignment member areconfigured to be seated within the first recess, to be seated within thesecond recess, to be seated within the third recess, and to be seatedwithin the fourth recess.

In some cases, the first male alignment member is seated within thefirst recess, the second male alignment member is seated within thethird recess, the first female alignment member is seated within thesecond recess, and the second female alignment member is seated withinthe fourth recess to allow the first modular frame and the first malealignment member to mate in a shipping arrangement with the secondmodular frame and the first female alignment member, to allow the firstmodular frame and the first male alignment member to mate in aninstalled arrangement with the second modular frame and the first femalealignment member, to allow the third modular frame and the second malealignment member to mate in a shipping arrangement with the fourthmodular frame and the second female alignment member, and to allow thethird modular frame and the second male alignment member to mate in aninstalled arrangement with the fourth modular frame and the secondfemale alignment member.

In other embodiments, a method of forming door lite frame systemscomprises casting a first modular frame between a first top mold portionand a first bottom mold portion, the first modular frame having a firstlength, a first width and a first recess, casting a second modular framebetween the first top mold portion and the first bottom mold portion,the second modular frame having a second recess and dimensions matchingthose of the first modular frame, casting a third modular frame betweena second top mold portion and a second bottom mold portion, the thirdmodular frame having a second length larger than the first length, asecond width larger than the first width, and a third recess, casting afourth modular frame between the second top mold portion and the secondbottom mold portion, the fourth modular frame having a fourth recess anddimensions matching those of the third modular frame, seating a firstmale alignment member within the first recess, a first female alignmentmember within the second recess, a second male alignment member withinthe third recess, and a second female alignment member within the fourthrecess, the first male alignment member having dimensions matching thoseof the second male alignment member and the first female alignmentmember having dimensions matching those of the second female alignmentmember, mating the first modular frame and the first male alignmentmember with the second modular frame and the first female alignmentmember in a shipping arrangement, and mating the third modular frame andthe second male alignment member with the fourth modular frame and thesecond female alignment member in a shipping arrangement.

In some cases, seating the first male alignment member within the firstrecess comprises seating a first male interlocking member including afirst plurality of arms within the first recess, seating the second malealignment member within the third recess comprises seating a second maleinterlocking member including a second plurality of arms within thethird recess, seating the first female alignment member within thesecond recess comprises seating a first female alignment memberincluding a first plurality of teeth within the second recess, seatingthe second female alignment member within the fourth recess comprisesseating a second female alignment member including a second plurality ofteeth within the fourth recess, mating the first modular frame and thefirst male alignment member with the second modular frame and the firstfemale alignment member in a shipping arrangement comprises mating thefirst modular frame and the first male alignment member with the secondmodular frame and the first female alignment member such that the firstplurality of arms do not engage with the first plurality of teeth, andmating the third modular frame and the second male alignment member withthe fourth modular frame and the second female alignment member in ashipping arrangement comprises mating the third modular frame and thesecond male alignment member with the fourth modular frame and thesecond female alignment member such that the second plurality of arms donot engage the second plurality of teeth.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIGS. 1-5 illustrate components of a door lite frame system according toat least one illustrated embodiment.

FIGS. 6A-6F, 7A-7F, and 8A-8D illustrate components of a door lite framesystem according to at least one illustrated embodiment.

FIGS. 9-15 illustrate a modular frame of a door lite frame systemaccording to at least one illustrated embodiment.

FIGS. 16-18 illustrate a modular frame of a door lite frame systemaccording to at least one illustrated embodiment.

FIGS. 19-23 illustrate a modular frame of a door lite frame systemaccording to at least one illustrated embodiment.

FIGS. 24-26 illustrate a modular frame of a door lite frame systemaccording to at least one illustrated embodiment.

FIGS. 27-32 illustrate a mold system according to at least oneillustrated embodiment.

FIGS. 33-35 illustrate coupling components of a door lite frame systemto a modular frame of the door lite frame system according to at leastone illustrated embodiment.

DETAILED DESCRIPTION

FIG. 1 illustrates an example of a door lite frame system 10 including amodular frame 20 and a modular frame 30. The modular frame 20 is coupledto a plurality of male alignment members 40 and a plurality of maleinterlocking members 50, each adjacent to a respective male alignmentmember 40. A male alignment member 40 can include a rectangular shaftextending outward from the modular frame 20. A male interlocking member50 can include a rectangular shaft extending outward from the modularframe 20 and a plurality of arms 55 extending away from the rectangularshaft toward the respective male alignment member 40. A male alignmentmember 40 and a respective male interlocking member 50 can together bereferred to as a male alignment and interlocking member. The modularframe 30 is coupled to a plurality of female alignment members 60, eachfemale alignment member 60 including a plurality of teeth 65 coupled toa first side of a hollow rectangular shaft opposite a second side of thehollow rectangular shaft. In some embodiments, the modular frame 20 canbe identical to the modular frame 30, can have dimensions matching thoseof the modular frame 30, or can be fabricated from the same mold as usedto fabricate the modular frame 30.

FIG. 2 illustrates a corner portion of the modular frame 20 and two malealignment and interlocking members in greater detail. FIG. 3 illustratesa corner portion of the modular frame 30 and two of the female alignmentmembers 60 in greater detail. The female alignment members 60 caninclude hollow elements which can be configured to receive respectivemale alignment members 40 in either one of two different orientations.Further, the male and female alignment members 40, 60, can be positionedaround the modular frames 20, 30, respectively, such that as the modularframes 20, 30 are brought toward one another, each male alignment member40 enters a respective female alignment member 60.

For example, the modular frame 20 can be aligned with the modular frame30 in a first aligned configuration such that the modular frames 20, 30can be brought toward one another until the male alignment members 40enter respective female alignment members 60 such that the arms 55 ofeach male alignment member 40 are adjacent the second side of arespective female alignment member 60, such that the teeth 65 do notengage the arms 55. Such an arrangement can be referred to as anunlocked, shipping arrangement because the modular frame 20 and themodular frame 30 are not locked to one another and can be pulledlaterally apart from one another. In such an arrangement, engagement ofthe male and female alignment members 40, 60 can align the modularframes 20, 30 with one another, such as during transportation of theframe system 10 to an installation location.

As another example, the modular frame 20 can be aligned with the modularframe 30 in a second aligned configuration such that the modular frames20, 30 can be brought toward one another until the male alignmentmembers 40 enter respective female alignment members 60 such that thearms 55 of each male alignment member 40 are adjacent the first side ofa respective female alignment member 60, such that the teeth 65 doengage the arms 55. Such an arrangement is illustrated in FIG. 4 and ingreater detail in FIG. 5, and can be referred to as a locked, installedarrangement because the modular frame 20 and the modular frame 30 arelocked to one another and cannot be pulled laterally apart from oneanother without breaking one or more components of the frame system 10.In such an arrangement, engagement of the male and female alignmentmembers 40, 60 can align the modular frames 20, 30 with one another, andengagement of the teeth 65 with the arms 55 can lock the modular frames20, 30 to one another.

In some embodiments, the modular frames 20, 30 can be progressivelybrought toward one another and the arms 55 can progressively engage theteeth 65 to progressively lock the modular frames 20, 30 to one another.Thus, in different implementations, the modular frames 20, 30 can belocked together in the locked, installed arrangement with differentdistances between the modular frames 20, 30. The different distancesbetween the modular frames 20, 30 allow glass or glazing of differentthicknesses to be held in place between an inner surface 90 of themodular frame 20 and an inner surface 95 of the modular frame 30, andcan likewise allow the frame system 10 to be used with doors or otherstructures of different thicknesses.

The frame system 10 can be configured such that the orientation of themodular frame 20 in the first aligned configuration is rotated 180° withrespect to the modular frame 30 from the orientation of the modularframe 20 in the second aligned configuration. Thus, a method ofinstalling the frame system 10 can include fabricating the individualcomponents of the system 10, coupling the components to one another asshown in FIG. 1, shipping the frame system 10 in the unlocked, shippingarrangement to an installation location, pulling the modular frames 20,30 laterally away from one another, and coupling the modular frames 20,30 to one another in the locked, installed arrangement with a windowbetween them. For example, a piece of material such as glass or glazingcan be held in place between the inner surface 90 of the modular frame20 and the inner surface 95 of the modular frame 30.

As illustrated in FIGS. 1-5, a first modular frame 20 of the system 10can be coupled to male alignment members 40 and male interlockingmembers 50 but not to female alignment members 60, and a second modularframe 30 of the system 10 can be coupled to female alignment members 60but not to male alignment members 40 or male interlocking members 50. Inother embodiments, however, a first modular frame of a frame system canbe coupled to one or more male alignment members 40, one or more maleinterlocking members 50, and one or more female alignment members 60,and a second modular frame of the frame system can be coupled to one ormore male alignment members 40, one or more male interlocking members50, and one or more female alignment members 60.

In some specific embodiments, a first modular frame of a frame systemcan be coupled to one or more male alignment members 40, one or moremale interlocking members 50, and one or more female alignment members60, and an identical second modular frame of the frame system can beidentically coupled to one or more male alignment members 40, one ormore male interlocking members 50, and one or more female alignmentmembers 60, such that the first modular frame and the members coupledthereto are identical to the second modular frame and the memberscoupled thereto. In some embodiments, the positions of the malealignment members 40, male interlocking members 50, and female alignmentmembers 60 on the first modular frame can correspond to those on thesecond modular frame such that the first and second modular frames canbe coupled to one another in an unlocked, shipping arrangement, and in alocked, installed arrangement as described above.

As illustrated in FIGS. 1-5, a first modular frame 20 of the system 10can be coupled to male alignment and interlocking members facing thesame direction, i.e., such that the male alignment members 40 and themale interlocking members 50 alternate along each side of the modularframe 20. Similarly, the second modular frame 30 of the system 10 can becoupled to female alignment members 60 facing the same direction, i.e.,such that the first side of each female alignment member 60 faces thesecond side of an adjacent female alignment member 60 or such that thefirst side of each female alignment member 60 does not face a first sideof an adjacent female alignment member 60. In other embodiments,however, a first modular frame of a frame system can be coupled to malealignment and interlocking members facing in different or alternatingdirections. Similarly, a second modular frame of the frame system can becoupled to one or more female alignment members 60 facing in differentor alternating directions. In such embodiments, the positions andorientations of the male alignment members 40, male interlocking members50, and female alignment members 60 on the first modular frame cancorrespond to those on the second modular frame such that the first andsecond modular frames can be coupled to one another in an unlocked,shipping arrangement, and in a locked, installed arrangement asdescribed above.

It has been found that a convenient and economical method of fabricatingthe components of the frame system 10 is doing so modularly. Morespecifically, it has been found that fabricating a single integralcomponent that includes both of the modular frame 20 and the malealignment and interlocking member or a single integral component thatincludes both of the modular frame 30 and the female alignment member 60can be unnecessarily expensive, for several reasons. First, injectionmolding of such integral members can use complex molds and one or moreside pulls, which can increase the cost of the molds and fabricationprocess. Second, two separate molds are often used—one for the integralcomponent that includes the modular frame 20 and the male alignment andinterlocking member and another for the integral component that includesthe modular frame 30 and the female alignment member 60—in effectdoubling the cost of the already expensive molds. Third, two of suchexpensive molds are used for each size of door lite to be fabricated.Thus, to manufacture a 24″×36″ window, a 28″×54″ window, and a 34″×46″window, six expensive molds may be used. In contrast, it has been foundthat modular fabrication of components of door lite systems can reducemold costs by greater than 50%, and in some cases, even up to about 75%.

In some embodiments, the modular frame 20 can be formed without theplurality of male alignment members 40 and without the plurality of maleinterlocking members 50, and the modular frame 30 can be formed withoutthe plurality of female alignment members 60. The plurality of malealignment members 40, the plurality of male interlocking members 50, andthe plurality of female alignment members 60 can be formed separatelyfrom the other components of the frame system 10. The plurality of malealignment members 40 and the plurality of male interlocking members 50can then be coupled to the modular frame 20, and the plurality of femalealignment members 60 can be coupled to the modular frame 30. The framesystem 10 can then be shipped in the unlocked, shipping arrangement toan installation location, the modular frames 20, 30 can be pulledlaterally away from one another, and the modular frames 20, 30 can thenbe coupled to one another in the locked, installed arrangement with awindow between them.

In some cases, the modular frame 20 can be formed without the pluralityof male alignment members 40 and without the plurality of maleinterlocking members 50 by injection moldingacrylonitrile-butadiene-styrene (ABS) between no more than two opposedmold portions. In some cases, the modular frame 30 can be formed withoutthe plurality of female alignment members 60 by injection moldingacrylonitrile-butadiene-styrene (ABS) between no more than two opposedmold portions. In some cases, the plurality of male alignment members40, the plurality of male interlocking members 50, and the plurality offemale alignment members 60 can each be formed separately from the othercomponents of the frame system 10 by injection moldingacrylonitrile-butadiene-styrene (ABS) between no more than two opposedmold portions. In some cases, each male alignment member 40 can beformed integrally with a respective male interlocking member 50 butseparately from the other components of the frame system 10 by injectionmolding acrylonitrile-butadiene-styrene (ABS) between no more than twoopposed mold portions to form a male alignment and interlocking member.

FIG. 6A illustrates a cross-sectional side view, FIG. 6B an end view,FIG. 6C a side view, FIG. 6D a top view, FIG. 6E a first perspectiveview, and FIG. 6F a second perspective view of one embodiment of a malealignment and interlocking member 100 including a male alignment member42 similar to male alignment member 40 and a male interlocking member 52similar to male interlocking member 50 that was formed separately fromthe other components of the frame system of which it forms a part. FIG.7A illustrates a cross-sectional side view, FIG. 7B an end view, FIG. 7Ca side view, FIG. 7D a top view, FIG. 7E a first perspective view, andFIG. 7F a second perspective view of one embodiment of a femalealignment member 62 similar to female alignment member 60 that wasformed separately from the other components of the frame system of whichit forms a part. FIG. 8A illustrates a perspective view, FIG. 8B a sideview, FIG. 8C an end view, and FIG. 8D a top view of one embodiment of aspacer element 80 that was formed separately from the other componentsof the frame system of which it forms a part.

The dimensions provided in FIGS. 6A-6F, 7A-7F, and 8A-8D have units ofmillimeters (as do the dimensions provided in all of the Figures), andare examples of dimensions that have been found to be suitable. Thesedimensions are not intended to limit the scope of the disclosure. Asillustrated, a length of the male alignment and interlocking member 100can be the same as the combined length of the female alignment member 62and the spacer element 80, such that the male alignment and interlockingmember 100 can be mounted interchangeably with the combination of afemale alignment member 62 and a spacer element 80 to another portion ofa frame system such as a recess of a modular frame.

FIG. 9 illustrates a perspective view, FIG. 10 a top view, FIG. 11 aside view, FIG. 12 a cross-sectional side view taken along line A-Ashown in FIG. 10, FIG. 13 an end view, FIG. 14 a first cross-sectionalend view taken along line B-B shown in FIG. 10, and FIG. 15 a secondcross-sectional end view taken along line C-C shown in FIG. 10 of afirst embodiment of a modular frame 110 formed separately from the othercomponents of the frame system of which it forms a part. Modular frame110 can be similar to modular frame 20 or modular frame 30. In somecases, the modular frame 110 can be formed by injection moldingacrylonitrile-butadiene-styrene (ABS) between no more than two opposedmold portions.

The modular frame 110 includes a rectangular frame 112 with a centralrectangular opening 114. The rectangular frame 112 includes a pluralityof recesses 116 which can form seats into which a male alignment andinterlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member 60,and/or a spacer element similar to spacer element 80 can be mounted. Insome cases, a first modular frame 110 can be coupled to a plurality ofsuch male alignment and interlocking members (i.e., the male alignmentand interlocking members can be mounted within the recesses 116 of thefirst modular frame 110) and a second modular frame 110 can be coupledto a plurality of such female alignment members and respective spacerelements (i.e., the female alignment members and respective spacerelements can be mounted within the recesses 116 of the second modularframe 110). The first and second modular frames 110, coupled to suchcomponents, can form a door lite frame system similar to door lite framesystem 10.

The modular frame 110 is illustrated having certain dimensions, and themodular frame 110 can have various alternative dimensions. In somecases, the modular frame 110 can have a larger overall length or width,so as to form a part of a larger door lite system, while otherdimensions of the modular frame 110 remain the same as thoseillustrated. In other cases, the modular frame 110 can have a smalleroverall length or width, so as to form a part of a smaller door litesystem, while other dimensions of the modular frame 110 remain the sameas those illustrated. In either case, a male alignment member, a maleinterlocking member, a male alignment and interlocking member, a femalealignment member, and/or a spacer element can be coupled to the modularframe 110 regardless of its overall length and width.

FIG. 16 illustrates a portion of a top view, FIG. 17 a firstcross-sectional end view taken along line 1-1 shown in FIG. 16, and FIG.18 a second cross-sectional end view taken along line 2-2 shown in FIG.16 of a second embodiment of a modular frame 120 formed separately fromthe other components of the frame system of which it forms a part. Themodular frame 120 can be similar to modular frame 20 or modular frame30. In some cases, the modular frame 120 can be formed by injectionmolding acrylonitrile-butadiene-styrene (ABS) between no more than twoopposed mold portions.

The modular frame 120 includes a rectangular frame 122 with a centralrectangular opening 124. The rectangular frame 122 includes a pluralityof recesses 126 which can form seats into which a male alignment andinterlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member 60,and/or a spacer element similar to spacer element 80 can be mounted. Insome cases, a first modular frame 120 can be coupled to a plurality ofsuch male alignment and interlocking members (i.e., the male alignmentand interlocking members can be mounted within the recesses 126 of thefirst modular frame 120) and a second modular frame 120 can be coupledto a plurality of such female alignment members and respective spacerelements (i.e., the female alignment members and respective spacerelements can be mounted within the recesses 126 of the second modularframe 120). The first and second modular frames 120, coupled to suchcomponents, can form a door lite frame system similar to door lite framesystem 10.

The modular frame 120 is illustrated having certain dimensions, and themodular frame 120 can have various alternative dimensions. In somecases, the modular frame 120 can have a larger overall length or width,so as to form a part of a larger door lite system, while otherdimensions of the modular frame 120 remain the same as thoseillustrated. In other cases, the modular frame 120 can have a smalleroverall length or width, so as to form a part of a smaller door litesystem, while other dimensions of the modular frame 120 remain the sameas those illustrated. In either case, a male alignment member, a maleinterlocking member, a male alignment and interlocking member, a femalealignment member, and/or a spacer element can be coupled to the modularframe 120 regardless of its overall length and width.

FIG. 19 illustrates a top perspective view, FIG. 20 a bottom perspectiveview, FIG. 21 a top view, FIG. 22 a cross-sectional end view taken alongline A-A shown in FIG. 21, and FIG. 23 a cross-sectional end view takenalong line B-B shown in FIG. 21 of a third embodiment of a modular frame130 formed separately from the other components of the frame system ofwhich it forms a part. Modular frame 130 can be similar to modular frame20 or modular frame 30. In some cases, the modular frame 130 can beformed by injection molding acrylonitrile-butadiene-styrene (ABS)between no more than two opposed mold portions.

The modular frame 130 includes a rectangular frame 132 with a centralrectangular opening 134. The rectangular frame 132 includes a pluralityof recesses 136 which can form seats into which a male alignment andinterlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member 60,and/or a spacer element similar to spacer element 80 can be mounted. Insome cases, a first modular frame 130 can be coupled to a plurality ofsuch male alignment and interlocking members (i.e., the male alignmentand interlocking members can be mounted within the recesses 136 of thefirst modular frame 130) and a second modular frame 130 can be coupledto a plurality of such female alignment members and respective spacerelements (i.e., the female alignment members and respective spacerelements can be mounted within the recesses 136 of the second modularframe 130). The first and second modular frames 130, coupled to suchcomponents, can form a door lite frame system similar to door lite framesystem 10.

The modular frame 130 is illustrated having certain dimensions, and themodular frame 130 can have various alternative dimensions. In somecases, the modular frame 130 can have a larger overall length or width,so as to form a part of a larger door lite system, while otherdimensions of the modular frame 130 remain the same as thoseillustrated. In other cases, the modular frame 130 can have a smalleroverall length or width, so as to form a part of a smaller door litesystem, while other dimensions of the modular frame 130 remain the sameas those illustrated. In either case, a male alignment member, a maleinterlocking member, a male alignment and interlocking member, a femalealignment member, and/or a spacer element can be coupled to the modularframe 130 regardless of its overall length and width.

FIG. 24 illustrates a portion of a top view, FIG. 25 a firstcross-sectional end view taken along line A-A shown in FIG. 24, and FIG.26 a larger view of a portion of FIG. 25 of a fourth embodiment of amodular frame 140 formed separately from the other components of theframe system of which it forms a part. Modular frame 140 can be similarto modular frame 20 or modular frame 30. In some cases, the modularframe 140 can be formed by injection moldingacrylonitrile-butadiene-styrene (ABS) between no more than two opposedmold portions.

The modular frame 140 includes a rectangular frame 142 with a centralrectangular opening 144. The rectangular frame 142 includes a pluralityof recesses 146 which can form seats into which a male alignment andinterlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member 60,and/or a spacer element similar to spacer element 80 can be mounted. Insome cases, a first modular frame 140 can be coupled to a plurality ofsuch male alignment and interlocking members (i.e., the male alignmentand interlocking members can be mounted within the recesses 146 of thefirst modular frame 140) and a second modular frame 140 can be coupledto a plurality of such female alignment members and respective spacerelements (i.e., the female alignment members and respective spacerelements can be mounted within the recesses 146 of the second modularframe 140). The first and second modular frames 140, coupled to suchcomponents, can form a door lite frame system similar to door lite framesystem 10.

The modular frame 140 is illustrated having certain dimensions, and themodular frame 140 can have various alternative dimensions. In somecases, the modular frame 140 can have a larger overall length or width,so as to form a part of a larger door lite system, while otherdimensions of the modular frame 140 remain the same as thoseillustrated. In other cases, the modular frame 140 can have a smalleroverall length or width, so as to form a part of a smaller door litesystem, while other dimensions of the modular frame 140 remain the sameas those illustrated. In either case, a male alignment member, a maleinterlocking member, a male alignment and interlocking member, a femalealignment member, and/or a spacer element can be coupled to the modularframe 140 regardless of its overall length and width.

FIG. 27 illustrates a top view, FIG. 28 a cross-sectional side viewalong line A-A shown in FIG. 27, FIG. 29 a cross-sectional end viewalong line B-B shown in FIG. 27, and FIG. 30 an end view of a moldsystem 150 for forming a modular frame for use in a door lite framesystem. The modular frame can be formed between a first, bottom moldplate 152 and a second, top mold plate 154 opposed to the first moldplate 152, such as within a void or cavity 156 defined between the moldplates 152, 154. FIG. 31 illustrates a three-dimensional representationof the mold system 150, and FIG. 32 illustrates an explodedthree-dimensional representation of the mold system 150. In some cases,the first mold plate 152 or the second mold plate 154 can have surfacepatterns formed thereon such that the modular frame formed in the moldsystem 150 has corresponding surface patterns.

FIG. 33 illustrates that a modular frame 180 similar to one of modularframes 110, 120, 130, or 140 can include a plurality of locator tabs 160positioned within its recess 182, similar to one of the recesses 116,126, 136, or 146. The locator tabs 160 can protrude outward from asurface 162 of the modular frame 180 to which other components will bemounted. The locator tabs 160 can be positioned within the recess 182 toguide a male alignment and interlocking member or a female alignmentmember and a spacer element into a desired location within the recess182. FIG. 34 illustrates that the locator tabs 160 can be used incombination with an adhesive such as an ABS structural adhesive 164. Insome cases, the ABS structural adhesive 164 can be used without thelocator tabs 160. In some cases, the ABS structural adhesive 164 canprovide a bond that is at least as strong as, or stronger than, solidABS material.

FIG. 35 illustrates that a modular frame 184 similar to one of modularframes 110, 120, 130, or 140 can include a plurality of angle elements166 such as steel angles positioned within its recess 186, similar toone of the recesses 116, 126, 136, or 146. The angle elements 166 caninclude a bottom leg portion 168 and a top leg portion 170 coupled tothe bottom leg portion 168 at a 90° angle. The angle elements 166 can beformed integrally with the modular frame 184 or can be formed separatelyfrom the modular frame 184 and coupled thereto, such as with an adhesivepositioned between the bottom leg portions 168 and the modular frame184. Each top leg portion 170 can function in a manner similar to thelocator tabs 160, as described above, and can also include a hole 172for receiving a fastener such as a screw 174. Once components, such as amale alignment and interlocking member, are seated within the recess 186between two top leg portions 170, screws 174 can be screwed through thetop leg portions 170 and into the components to secure them to themodular frame 184. The angle elements 166 can be used in combinationwith an adhesive such as an ABS structural adhesive, as shown in FIG.34, or without such an adhesive. In some cases, the angle elements 166and screws 174 can provide a bond that is at least as strong as, orstronger than, solid ABS material.

In some cases, modular door lite components in accordance with the abovedescription can be provided in systems or kits. For example, a system ofmodular door lite components can include two modular frames similar tomodular frames 20, 30, 110, 120, 130, and/or 140, a male alignment andinterlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member 60,and a spacer element similar to spacer element 80. A door lite systemcan be assembled from these components.

As another example, a system of modular door lite components can includetwo modular frames each having a first width and a first length, twomodular frames each having a second width and a second length, two malealignment and interlocking members having the same dimensions as oneanother, two female alignment members having the same dimensions as oneanother, and two spacer elements having the same dimensions as oneanother. The first width can be larger or smaller than the second width,and the first length can be larger or smaller than the second length.Two door lite systems having different overall dimensions can beassembled from these components.

The modular door lite components described herein can be used toassemble door lites at less expense than previous door lite systems. Thereduced expense can be attributed to at least the modular nature of thecomponents and to reduced manufacturing costs associated with theelimination of side pulls and the use of no more than two opposed moldportions to form the components. The methods, systems, and devicesdescribed herein can be used to turn metal frames into energy efficient(thermal break) snap frames.

The various embodiments described above can be combined to providefurther embodiments. All of the U.S. patents, U.S. patent applicationpublications, U.S. patent applications, foreign patents, foreign patentapplications and non-patent publications referred to in thisspecification and/or listed in the Application Data Sheet, includingU.S. patent application Ser. No. 14/643,861, filed Mar. 10, 2015, areincorporated herein by reference, in their entirety. Aspects of theembodiments can be modified, if necessary to employ concepts of thevarious patents, applications and publications to provide yet furtherembodiments.

These and other changes can be made to the embodiments in light of theabove-detailed description. In general, in the following claims, theterms used should not be construed to limit the claims to the specificembodiments disclosed in the specification and the claims, but should beconstrued to include all possible embodiments along with the full scopeof equivalents to which such claims are entitled. Accordingly, theclaims are not limited by the disclosure.

1-6. (canceled)
 7. A method of forming door lite frame systemscomprising: casting a first modular frame between a first top moldportion and a first bottom mold portion, the first modular frame havinga first length, a first width and a first recess; casting a secondmodular frame between the first top mold portion and the first bottommold portion, the second modular frame having a second recess anddimensions matching those of the first modular frame; casting a thirdmodular frame between a second top mold portion and a second bottom moldportion, the third modular frame having a second length larger than thefirst length, a second width larger than the first width, and a thirdrecess; casting a fourth modular frame between the second top moldportion and the second bottom mold portion, the fourth modular framehaving a fourth recess and dimensions matching those of the thirdmodular frame; seating a first male alignment member within the firstrecess, a first female alignment member within the second recess, asecond male alignment member within the third recess, and a secondfemale alignment member within the fourth recess, the first malealignment member having dimensions matching those of the second malealignment member and the first female alignment member having dimensionsmatching those of the second female alignment member; mating the firstmodular frame and the first male alignment member with the secondmodular frame and the first female alignment member in a shippingarrangement; and mating the third modular frame and the second malealignment member with the fourth modular frame and the second femalealignment member in a shipping arrangement.
 8. The method of claim 7,wherein: seating the first male alignment member within the first recesscomprises seating a first male interlocking member including a firstplurality of arms within the first recess; seating the second malealignment member within the third recess comprises seating a second maleinterlocking member including a second plurality of arms within thethird recess; seating the first female alignment member within thesecond recess comprises seating a first female alignment memberincluding a first plurality of teeth within the second recess; seatingthe second female alignment member within the fourth recess comprisesseating a second female alignment member including a second plurality ofteeth within the fourth recess; mating the first modular frame and thefirst male alignment member with the second modular frame and the firstfemale alignment member in a shipping arrangement comprises mating thefirst modular frame and the first male alignment member with the secondmodular frame and the first female alignment member such that the firstplurality of arms do not engage with the first plurality of teeth; andmating the third modular frame and the second male alignment member withthe fourth modular frame and the second female alignment member in ashipping arrangement comprises mating the third modular frame and thesecond male alignment member with the fourth modular frame and thesecond female alignment member such that the second plurality of arms donot engage the second plurality of teeth.
 9. The method of claim 8,further comprising: pulling the first modular frame and the first malealignment member laterally away from the second modular frame and thefirst female alignment member; pulling the third modular frame and thesecond male alignment member laterally away from the fourth modularframe and the second female alignment member; mating the first modularframe and the first male alignment member with the second modular frameand the first female alignment member in an installed arrangement; andmating the third modular frame and the second male alignment member withthe fourth modular frame and the second female alignment member in aninstalled arrangement.
 10. The method of claim 9, wherein: mating thefirst modular frame and the first male alignment member with the secondmodular frame and the first female alignment member in an installedarrangement comprises mating the first modular frame and the first malealignment member with the second modular frame and the first femalealignment member such that the first plurality of arms progressivelyengage with the first plurality of teeth; and mating the third modularframe and the second male alignment member with the fourth modular frameand the second female alignment member in an installed arrangementcomprises mating the third modular frame and the second male alignmentmember with the fourth modular frame and the second female alignmentmember such that the second plurality of arms progressively engage thesecond plurality of teeth.